Pinion Depth Adjustment
Adjust the pinion depth according to the following procedure:
| NOTICE |
|---|
The ring gear and pinion are a matched set. If either part is worn or damaged, both parts must be replaced with a matched set. |
Note: The following procedure for the pinion depth adjustment is only necessary if the ring gear and the pinion (bevel gear set) are replaced. The pinion depth adjustment may also be necessary if the axle housing is replaced.
| Required Tools | ||
|---|---|---|
| Qty | Part Number | Description |
| 1 | 125-9786 | Differential Tool Gp |
| 1 1 1 2 1 |
(1) Arbor (1) Cap (1) Datum Bar (1) Bolt (1) Bolt |
|
| 1 | 6V-6106 | Dial Indicator |
| 1 | 5P-4156 | Indicator Base |
| 1 | 3P-1565 | Collet Clamp |
| 1 | 5P-4161 | Indicator Contact Point 69.85 mm (2.75 inch) |
| 1 | 9U-5017 | Torque Wrench |
| 1 | 1P-0520 | Driver Gp |
| ( 1 ) | Included in 125-9786 Differential Tool Gp |
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| Illustration 1 | g00731445 |
Arrangement of the Pinion (1) Shim pack (pinion bearing preload adjustment) (2) Shim pack (pinion depth adjustment) (3) Axle housing (4) Nut (flange) (5) Ring nut (6) Outer roller bearing (7) Spacer (8) Inner roller bearing (9) Pinion | |
Before pinion (9) is installed into housing (3) , the correct pinion depth must be established. The pinion depth is controlled by the thickness of shim pack (2) . The formula that is used to determine the required shim pack thickness is shown below.
(2) Shim pack = W + X
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| Illustration 2 | g00731446 |
Location of Identification Number, Reference Information, and Dimension | |
Note: An identification number for pinion (9) is marked along the shaft of the pinion. A reference mark "ITN 113", which is a nominal figure, appears after the identification number for the pinion. A number is also marked onto the face of the pinion gear. Record the number that appears on your pinion as dimension "W".
- If the marking on pinion (9) has a negative symbol (-) with three digits "-0.02", change the negative symbol (-) to a positive symbol (+) . Record the altered number as dimension "W".
Example
- If the pinion has been marked "-0.02", record the measurement (+0.02 mm) as dimension "W".
If the marking on pinion (9) has a positive symbol (+) with three digits "+0.02", change the positive symbol (+) to a negative symbol (-) . Record the altered number as dimension "W".
Example
- If the pinion has been marked "+0.02", record the measurement (-0.02 mm) as dimension "W".
If the marking on pinion (9) has a "0.00" reference mark, this mark should be interpreted as the nominal figure of "113".
If there is no marking on the pinion (9) , this mark should be interpreted as the nominal figure of "113".
Example
- If the pinion has been marked "0.00", record the measurement (0 mm) as dimension "W".
- If the pinion has been marked "-0.02", record the measurement (+0.02 mm) as dimension "W".
- Refer to Illustration 3 and assemble the tools on a surface plate. Use two bolts in order to secure datum bar (14) to cap (12) . Place indicator base (15) into the slot of the datum bar. Assemble dial indicator (10) , collet clamp (11) , and indicator contact point (13) . Slide indicator contact point (13) through the hole in the datum bar. Set the gauge of the dial indicator to "zero".
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| Illustration 3 | g00731447 |
Dial Indicator and Tooling Setup (10) Dial indicator (11) Collet clamp (12) Cap (13) Indicator contact point (14) Datum bar (15) Indicator base | |
- Remove the two bolts that secure the datum bar to the cap and remove the cap. Remove the datum bar from the indicator base.
- Install the outer roller bearing (6) and the inner roller bearing (8) . Use the 1P-0504 Drive Plate (3.5-IN DIA) supplied in the 1P-0520 Driver Gp to properly seat the roller bearing cups into the axle housing. Before the bearings are installed, lightly lubricate the outer bearing cone and the inner bearing cone.
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| Illustration 4 | g00731449 |
Roller Bearings and Tooling Setup | |
- Install arbor (16) and cap (12) into the housing in order to retain the roller bearing cones. Secure the arbor to the cap with the bolt that is supplied with the 125-9786 Differential Tool Gp . Install the screw through the center hole in the cap.
Note: Do not install spacer (7) or shim pack (2) at this stage. Refer to Illustration 1 for the location of these parts.
- Use the 9U-5017 Torque Wrench in order to check that the rolling torque is 1.58 ± 0.11 N·m (14 ± 1 lb in).
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| Illustration 5 | g00731450 |
Checking the Rolling Torque | |
- Install dial indicator (10) , collet clamp (11) , indicator contact point (13) , and indicator base (15) onto datum bar (14) . Use the two bolts in order to secure the datum bar to cap (12) .
Note: Make sure that you sweep the indicator contact point across the inner bore of the axle housing. Record the lowest reading as dimension "X".
Example
A measurement of 0.45 mm is recorded as the dimension "X".
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| Illustration 6 | g00731451 |
Dial Indicator and Tooling Setup for Measuring Dimension "X" (10) Dial indicator (11) Collet clamp (12) Cap (13) Indicator contact point (14) Datum bar (15) Indicator base | |
- Remove all of the tooling from the axle housing.
- Add dimension "W" to dimension "X" in order to make up shim pack (2) of correct thickness. Install a shim pack of the calculated thickness into the position that is shown in Illustration 7.
Example
- W is equal to +0.02 mm.
X is equal to 0.45 mm.
Shim pack (2) is equal to W + X.
Therefore, shim pack (2) is equal to 0.45 + 0.02 mm = 0.47 mm (0.018 inch + 0.001 inch = 0.019 inch).
- W is equal to −0.02 mm.
X is equal to 0.45 mm.
Shim pack (2) is equal to W + X.
Therefore, shim pack (2) is equal to 0.45 - 0.02 mm = 0.43 mm (0.018 inch - 0.001 inch = 0.017 inch).
- W is equal to +0.02 mm.
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| Illustration 7 | g00731452 |
Position of Shim Pack for Pinion Depth Adjustment | |
Pinion Bearing Preload Adjustment
Adjust the pinion bearing preload according to the following procedure:
| Required Tools | ||
|---|---|---|
| Qty | Part Number | Description |
| 1 | 125-9786 | Differential Tool Gp |
| 1 1 1 2 1 |
(1) Arbor (1) Cap (1) Datum Bar (1) Bolt (1) Bolt |
|
| 1 | 6V-6106 | Dial Indicator |
| 1 | 5P-4156 | Indicator Base |
| 1 | 3P-1565 | Collet Clamp |
| 1 | 5P-4161 | Indicator Contact Point 69.85 mm (2.75 inch) |
| 1 | 9U-5017 | Torque Wrench |
| 1 | 1P-0520 | Driver Gp |
| 1 | 125-9787 | Spanner Wrench (Pinion Nut) |
| 1 | 125-9789 | Spline Wrench (Pinion Shaft) |
| ( 1 ) | Included in 125-9786 Differential Tool Gp |
 | |
| Illustration 8 | g00729000 |
Position of Shim Pack for Pinion Bearing Preload Adjustment (1) Shim pack (pinion bearing preload adjustment) (2) Shim pack (pinion depth adjustment) (3) Axle housing (4) Nut (flange) (5) Ring nut (6) Outer roller bearing (7) Spacer (8) Inner roller bearing (9) Pinion (17) Inner bearing cone | |
The pinion bearing preload is determined by the thickness of shim (1) that is installed on the shaft of pinion (9) . Shim (1) is installed between the inner bearing cone (17) and spacer (7) . The procedure that follows describes the calculation that is necessary in order to obtain the correct shim pack thickness.
- Install inner roller bearing (8) and outer roller bearing (6) into axle housing (3) . Install the following tooling into axle housing (3) : arbor (16) , cap (12) , dial indicator (10) , collet clamp (11) , indicator base (15) and indicator contact point (13) . After measuring, record the measurement of dimension "Y".
Note: Do not install shim pack (1) and spacer (7) at this stage. Refer to Illustration 8 for the location of these parts.
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| Illustration 9 | g00729006 |
Dial Indicator and Tooling Setup for Measuring Dimension "Y" (3) Axle housing (6) Outer roller bearing (8) Inner roller bearing (10) Dial indicator (11) Collet clamp (12) Cap (13) Indicator contact point (15) Indicator base (16) Arbor | |
- Remove all the tooling from the axle housing and the inner roller bearing cone and the outer roller bearing cone.
- Install inner roller bearing cone (17) , outer roller bearing cone (18) and spacer (7) onto arbor (16) . Position cap (12) onto the assembly and install the following tooling: dial indicator (10) , collet clamp (11) , indicator base (15) and indicator contact point (13) . After measuring, record the measurement of dimension "Z".
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| Illustration 10 | g00729010 |
Dial Indicator and Tooling Setup for Measuring Dimension "Z" (7) Spacer (10) Dial indicator (11) Collet clamp (12) Cap (13) Indicator contact point (15) Indicator base (16) Arbor (17) Inner roller bearing cone (18) Outer roller bearing cone | |
- In order to obtain the correct thickness for shim pack (1) , subtract dimension "Z" from dimension "Y" and add bearing preload dimension "P". The dimension for bearing preload "P" is 0.11 ± 0.01 mm (0.0043 ± 0.0004 inch). Therefore, the thickness of shim pack (1) is equal to Y − Z + P.
- Refer to Step 4 and assemble a shim pack (1) of calculated thickness.
Note: Shims are available in the following thicknesses: 0.35 mm (0.0138 inch), 0.40 mm (0.0157 inch), 0.45 mm (0.0177 inch), 0.50 mm (0.0197 inch), 0.55 mm (0.0217 inch) and 0.60 mm (0.0236 inch).
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| Illustration 11 | g00729000 |
Position of Shim Pack for Pinion Bearing Preload Adjustment (1) Shim pack (pinion bearing preload adjustment) (2) Shim pack (pinion depth adjustment) (3) Axle housing (4) Nut (flange) (5) Ring nut (6) Outer roller bearing (7) Spacer (8) Inner roller bearing (9) Pinion (17) Inner roller bearing cone | |
- Install inner roller bearing (8) , shim pack (1) , spacer (7) and outer roller bearing (6) into axle housing (3) .
- Install pinion (9) and apply 9S-3263 Thread Lock Compound to the threaded section of the pinion shaft. Install ring nut (5) and tighten to a torque setting of 650 ± 50 N·m (480 ± 37 lb ft). Use a 125-9787 Spanner Wrench (19) and a 125-9789 Spline Wrench (20) in order to tighten the ring nut.
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| Illustration 12 | g00731456 |
- Fully rotate the pinion and bearing assembly several times. Use a 9U-5017 Torque Wrench and check the rolling torque of the assembly. The rolling torque should be 1.5 ± 0.2 N·m (13.2761 ± 1.7702 lb in). Adjust shim pack (1) in order to obtain the required rolling torque. Increase the thickness of shim pack (1) in order to decrease the rolling torque. Decrease the thickness of shim pack (1) in order to increase the rolling torque.
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| Illustration 13 | g00731453 |
Checking the Rolling Torque of Pinion and Bearing Assembly | |